Offsore Wind Smart Drivetrain Lubrication Project...Maintenance cost 65 65 80 40 15 7 325,0000...

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Offsore Wind Smart Drivetrain Lubrication Project

Transcript of Offsore Wind Smart Drivetrain Lubrication Project...Maintenance cost 65 65 80 40 15 7 325,0000...

Page 1: Offsore Wind Smart Drivetrain Lubrication Project...Maintenance cost 65 65 80 40 15 7 325,0000 200,000 180,000 25000 3,000 3,000 Gearbox replacements Pitch bearing failure Main bearing

Offsore Wind Smart Drivetrain Lubrication Project

Page 2: Offsore Wind Smart Drivetrain Lubrication Project...Maintenance cost 65 65 80 40 15 7 325,0000 200,000 180,000 25000 3,000 3,000 Gearbox replacements Pitch bearing failure Main bearing

Smart Lubrication Drivetrain

Huge mechanical machine

Important moving parts

Page 3: Offsore Wind Smart Drivetrain Lubrication Project...Maintenance cost 65 65 80 40 15 7 325,0000 200,000 180,000 25000 3,000 3,000 Gearbox replacements Pitch bearing failure Main bearing

Smart Lubrication Drivetrain

Important mechanical moving parts:

• Main power train • Bearings• Gearbox

• Pitch power train• Motor• Planetary Gear Box • Gear Rings

• Yaw power train• Motor• Planetairy Gear Box • Gear rings

Page 4: Offsore Wind Smart Drivetrain Lubrication Project...Maintenance cost 65 65 80 40 15 7 325,0000 200,000 180,000 25000 3,000 3,000 Gearbox replacements Pitch bearing failure Main bearing

Smart Lubrication Drivetrain

• Downtime mainly caused by

• Gearbox

• Main bearings

• Yaw, and pitch system

• Failure cause:

Overload wear issues

Underload extensive slip of moving parts

Page 5: Offsore Wind Smart Drivetrain Lubrication Project...Maintenance cost 65 65 80 40 15 7 325,0000 200,000 180,000 25000 3,000 3,000 Gearbox replacements Pitch bearing failure Main bearing

Smart Lubrication Drivetrain

Page 6: Offsore Wind Smart Drivetrain Lubrication Project...Maintenance cost 65 65 80 40 15 7 325,0000 200,000 180,000 25000 3,000 3,000 Gearbox replacements Pitch bearing failure Main bearing

Maintenance costPlanned VS Unplanned maintenance

EVOLUTION COST TIME

Grease pitch and yaw bearings

USD 600 per wind turbine

generator12 man-

hoursGrease main bearing

Grease generator bearings

Semi annual/annual planned maintenance

Page 7: Offsore Wind Smart Drivetrain Lubrication Project...Maintenance cost 65 65 80 40 15 7 325,0000 200,000 180,000 25000 3,000 3,000 Gearbox replacements Pitch bearing failure Main bearing

Maintenance cost

65

65

80

40

15

7

325,0000

200,000

180,000

25000

3,000

3,000

Gearbox

replacements

Pitch bearing

failure

Main bearing

failure

Gearbox

repairs

Pitch/yaw

drive failure

Electrical

failures

Cost of component failures (USD/hours)

Cost per event USD

Avg. Man hours

Planned VS Unplanned maintenance

Failure rate ~3 %

Page 8: Offsore Wind Smart Drivetrain Lubrication Project...Maintenance cost 65 65 80 40 15 7 325,0000 200,000 180,000 25000 3,000 3,000 Gearbox replacements Pitch bearing failure Main bearing

Smart Lubrication Drivetrain

• Necessary – developing smart lubrication – drive train

• Autonomous system – zero downtime – zero maintenance – avoid people at sea

• Autonomous technology – sensors Data Information

• Take action only when needed

Page 9: Offsore Wind Smart Drivetrain Lubrication Project...Maintenance cost 65 65 80 40 15 7 325,0000 200,000 180,000 25000 3,000 3,000 Gearbox replacements Pitch bearing failure Main bearing

Smart Lubrication Drivetrain

• Oil degradation and wear particles indicates that a gearbox has a problem

• Vibrations indicates that a (main) bearing has a problem

• Warning only actions when abnormal conditions

• Combining data from multiple sensors

Page 10: Offsore Wind Smart Drivetrain Lubrication Project...Maintenance cost 65 65 80 40 15 7 325,0000 200,000 180,000 25000 3,000 3,000 Gearbox replacements Pitch bearing failure Main bearing

Smart Lubrication Drivetrain information

Page 11: Offsore Wind Smart Drivetrain Lubrication Project...Maintenance cost 65 65 80 40 15 7 325,0000 200,000 180,000 25000 3,000 3,000 Gearbox replacements Pitch bearing failure Main bearing

Why statistical condition monitoring?

Autonomous

system

Page 12: Offsore Wind Smart Drivetrain Lubrication Project...Maintenance cost 65 65 80 40 15 7 325,0000 200,000 180,000 25000 3,000 3,000 Gearbox replacements Pitch bearing failure Main bearing

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Lubricants itself: Automotive/Conventional/High Performance

• Conventional lubricants–meet specifications–minimum requirements

• High performance lubricants are formulated on maximum requirements

• Conventional lubricants 1-3% additives

• High perfomance lubricants

• maximum 30% additives

• HQ base oils

• Longer lifetime – less wear – smarter lubrication

Page 13: Offsore Wind Smart Drivetrain Lubrication Project...Maintenance cost 65 65 80 40 15 7 325,0000 200,000 180,000 25000 3,000 3,000 Gearbox replacements Pitch bearing failure Main bearing

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Smarter lubrication

• Friction reduction

• Higher effciency –power curve improvement

• Longer lifetime of lubricant

• Less wear

• Longer lifetime of rotating parts

• No manual regreasing

• Less maintenance

• Less/no people at sea

Page 14: Offsore Wind Smart Drivetrain Lubrication Project...Maintenance cost 65 65 80 40 15 7 325,0000 200,000 180,000 25000 3,000 3,000 Gearbox replacements Pitch bearing failure Main bearing

Contact details

Van Meeuwen Industries B.V.

[email protected]

+32(0)53 76 76 00 (Antwerpen, België)

+31(0)294 494 494 (Weesp, Nederland)

Taco Mets

[email protected]

+31(6)22528952 (mob.)

mailto:[email protected]
mailto:[email protected]

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